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CONWAY

OWNERS

MANUAL ' .

www.foldingcampers.net

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l_-: CONWAY

SECTION PAGE 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . 1 2. Prep aring for Use . . . . . . . . . . . . . . . . . . . . . ...... 2

- Weathering- Groundsheet Fitting· Framework Identification

3. Preparing for the Road ...- Hitch Weight ond Loading- Things to Check

. ..... 3

4. Towing and the Law .... . ........ 4 S. Pitching

- General- Trailer Tents· The Main Aim - Tout Canvas- Pegging Points & Guy lines- Internal· Pitching - Folding Campers- Levelling- Guy Points· Door Opening- Trouble Shooting - All Models· Condensation- Zips· Loose Convos

... 5- 9

6. �fr�tt��e�:ste . . . . . . . . . . . . . . . . . . .............. 1 o

- Folding Campers7. Canvas Care ............................ 11 -12

- Shrinkage- Wet Patches- Soiling· Cleaning and Re-Proofing- Inner Tents, Lining and Curtains- Mildew

8. Frame Care .............................. 13-14 Frame maintenance - Pole Connecting Springs ond Button Clips· Cabin Frome Hinge Points

INDEX

SECTION PAGE 9. Trailer Care -All Models ................. 15

· Trailer Tents- Body Panels Outside/Inside- Chassis and Drowbar Painted- Chassis and Drowbar Golvonised- Upholstery and Carpets- Folding Campers- Body Panels Outside/Inside- Chassis and Drowbar Galvanised· Upholstery and Carpets

10. Winter Storage . .................. . 16 - T miler Tents- Folding Campers· All Moaels

11. Gas App liances ............. ........... 17 -19 - Gos lntormotion- Trailer Tents- Folding Campers- Fridge· Unde�loor Heater- Combination Cooker Units- Gas System

12. Electrics ....- 12V Wiring - 12N and l 2S - 240V Mains - Cable Wiring

13. Chassis and Running Gear .- Axle - Description ond Operation- Overrun Coupling - Servicing

..... 20- 21

. .... 22- 27

- Broking System - Description and Operation- Broke Adjustment and Servicing- Wheel Bearings and Servicing

14. Ty res and Roadwheels ........... .... 28- 2_9_ - Tyre and Tyre Pressure Tobie- Wheels- Wheel Bolts and Nuts- Punctures and Changing Wheels


INTRODUCTION CONWAY

Dear Owner,

Thank you for buying Conway, we trust the hints and information in this handbook will enhance your knowledge of the product, thereby giving you and your family many happy years of enjoyable camping.

This handbook is intended to be a general guide to the safe use, care and maintenance of your trailer tent or folding camper.

Due to a poHcy of continual improvements and updates of appliances fitted to Conway units such as fridges, cookers, heaters and electrical components, specific user instructions· supplied by the appliance manufacturers, have been enclosed in addition to this handbook. All trailers are inspected before leaving the factory. By now you should have inspected your unit along with the dealer to confirm its condition and contents before leaving his premises.

We regret that Conway cannot be held responsible for any expense incurred by failure to inspect the unit and its contents or to weather the canvas fully before use. Any queries you may have, which are not covered by this handbook should first be addressed to your Conway appointed dealer.

Any queries that your dealer cannot resolve should be placed in writing to Conway Products quoting dealer, model number and serial number, (which can be found on the chassis plate fixed to the chassis), and date purchased.

P.S.P. Knight

Managing Director - Conway Products Limited


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'-. CONWAY

WEATHERING - Essential Before Use Any new trailer tent/folding camper that hos a cotton canvas may possibly leak at the seams, roof tie tapes and curtain and door ties or let fine spray through the roof and walls when subjected to heavy rain for the first time. This is perfectly normal for a new un·weothered canvas.

Controlled weathering is needed to overcome this situation before use on holiday.

The canvas hos been specially woven and dyed and finally impregnated by submersion in a waterproofing agent. However, it is not until the new fibres hove been in contact with water, causing initial shrinkage and therefore tightening of the weave and needle holes along the seams that the canvas can be considered weathered.

Choose a calm day but preferably not a very hot dry day. A showery day is ideal and following the step by step instructions erect the whole unit in any convenient area and securely peg out the canvas.

IU,)ij It is important to extend the cabin

frame fully (see the relevant section on pitching).

Now thoroughly soak the complete canvas. In the absence of rain use a hosepipe with a fine spray. Two or three soakings with a slow drying out period between them should be accomplished within the day if possible and is all that is normally necessary to weather a canvas. Ensure the canvas is thoroughly dry before pocking owoy especially under zip flops, tape edges and main seams.

PREPARING FOR USE

THINGS TO DO- During the Drying Period

Groundsheet Fitting Loy out the groundsheet evenly, ensuring the edges lay on top of the internal mudwoll which is sewn to the bottom edge of the walls. If the groundsheet hos corner eyelets fitted then pegs con be pushed through these and the Conway mudwoll material itself. If on your model this material is a coated polyester (PVA) it will not tear easily and the rough and ready holes you make will be sufficient, although some people may wish to complete the job by fitting DIY plastic or brass eyelets (available from comping retai lers) During this task you will notice that the extension or owning frame legs stand on either groundsheet or mudwoll material, i f you wish to change this then slit the mudwoll only with a sharp DIY knife at these points allowing the foot of the leg to rest directly on the ground below.

Important: If your mode.I hos mudwolls mode from unsupported PVC then greater care is needed. Use plastic eyelets only. Your dealer will advise you of the type of mudwoll material used for your model.

Framework - Extension or Awning Although many of the poles will be spring linked together you may wish to put identifying marks on these ond also the loose sections of poles, once they ore assembled correctly. This is also on ideal opportunity to ensure that the frame is the correct one for your unit and that it is complete ond undamaged before you intended to use it on holiday.

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PREPARING FOR THE ROAD

THE FOLLOWING IS A SIMPLE CHECK LIST

OF ESSENTIALS TO BE COMPLETED

BEFORE YOU MOVE OFF:

HITCH WEIGHT AND LOADING

Hitch weight or nose weight is the downward force your stationary trai ler places on your tow vehicle tow-bar /tow-ball.

The trailer tent is designed so that the hitch end is nose heavy, thus preventing snaking, so ensure you pack your goods in the trailer and the kitchen unit to maintain a nose heavy condition. if your model is the De Luxe with the kitchen unit fitted, ensure you do not exceed the maximum weight shown on the kitchen unit. It is not recommended thot the gos bottle be carried in the kitchen unit, unless your kitchen hos been designed by Conway to hove o specific gos bottle section, with o restraining strap and base plate.

The some rules opply to your folding camper, distribute the load evenly to achieve a nose weight of l 00-l 201bs. The nose weight can be reasonably checked on bathroom scales, with the trailer level.

It is advisable to check your tow vehicles handbook for recommended maximum hitch weight.

C:: CONWAY

THINGS TO CHECK

Most of the things are straight forward, this list is just a reminder:

a. BRAKED MODELS_ - check the hitch is correctlyengaged and the breakaway cable is connected to thetowing vehicle.

UN-BRAKED MODELS - check the hitch iscorrectly engaged and the secondary coupling (safetycable) ,if fitted, is connected to the towing vehicle.

b. Connect the 7 pin plug(s) and ensure your lights andindicators are working correctly.

c. · Check tyre pressures, it is important to hove correctminimum pressure. (See Tyre Pressure Tobie)

d. Check wheel nuts/wheel bolts (see wheels section).

e. Check that the corner steadies and jack legs are woundup fully and secured properly. A corner steady brace issupplied with each unit.

f. Ensure the jockey wheel, if fitted, is wound up securely,then lifted up fully and securely clomped.

g. If brakes ore fitted, ensure they are properly released,with the handbrake completely off.

h. If o cover is fitted, make sure it is properly secured.

i. Where a De Luxe kitchen is fitted, make sure the unit issecured and the 7 pin plug is connected for the roodlights.

j. With o folding camper, close all cupboards, secure gascylinders and in the case of o solid roof, make sure theroof is properly secured and roof vent closed andinternal lights switched off.

k. Check your wing mirrors.

HAVE A SAFE JOURNEY AND ENJOY

CONWAY CAMPING.


c� CONWAY TOWING AND THE LAW

GENERAL INFORMATION FOR ALL MODELS HINTS ON TOWING

To comply with the law (UK) for towing up to the maximum speed of 60mph YOU MUST ENSURE THAT:

a. The maximum gross weight being towed does NOTEXCEED the vehicle manufacturers towing weightspecified in the towing vehicle handbook.

b. If brakes are NOT fitted to the trailer, the gross weightof the trailer should not exceed 7 50kg and also thatthe towing vehicle kerb weight must be at least twicethe gross weight of the trailer.

e.g. Car kerb weight - 1000kgMaximum gross trailer weight - 500kg

c. If brakes are fitted to the trailer comments in point'a' apply.

d. The trailer must be fitted with a plate on the nearsidepermanently marked with the gross maximum trailerweight, as on our chassis plate.

e. When towing on a motorway or dual carriageway youobserve the maximum speed of 60mph unless a lowerspeed limit is in force.

f. When towing on any other road you observe themaximum speed limit of 50mph unless a lower limit isin force on that road.

g. It is illegal to tow in the outside lane of a three or morelane motorway.

TOWING A TRAILER TENT OR

FOLDING CAMPER SHOULD

PRESENT NO PROBLEMS IF YOU:

a. Allow yourse� time to get used to the feel · ofthe tow vehicles handling now thot it is towingthe extra weight of the trailer.

b. Allow extra time and distance for braking andovertaking.

c. Equip your tow vehicle with extending wing ordoor mirrors when towing the longer and widerfolding camper models.

d. Practice reversing the trailer, in some quiet 'offroad' location - not on a camp site!

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PITCHING

GENERAL

Wherever possible, choose a level pitch, avoiding low lying areas that could hold water during and after heavy rain.

Avoid pitching directly underneath trees, they hold dust which is washed off when it rains, secrete sticky sap and continue to shed water long after the rain has stopped, all to the detriment of your canvas.

Never unfold or wrap canvas directly on the ground, no matter how dry or clean it appears, use your groundsheet or a sheet of plastic. This is a main cause of a contaminated canvas and subsequent cause of future leaking.Oil drips from vehicles, cooking oil, fat spills, grease of any kind, carelessly discarded washing up water or water containing detergents, even chi ld ren's blow-bubble residue can adversely effect your canvas.

Check the pitch site for the above plus any sharp stones, sticks, discarded or un-pulled pegs, they can all damage your canvas and groundsheet.

Walls, hedges, trees, all make excellent windbreaks.

TRAILER TENTS

Wherever possible point the drawbor end to the prevailing wind, this way the extension canvas with its main doorways is less exposed.

Because of the basic need for a stable trailer unit before the canvas and frame are erected it is necessary to overcome the natural flexing of the trailer suspension unit i.e. the rubber in torsion axle unit.

er: CONWAY

it't,Jjj With or without the benefit of a ;ockey

wheel or wind down corner steadies, assistance will be

needed at certain points of the procedure.

The easiest way to do this is as follows:-a. Having chosen the exact spot for pitching, with the

trailer os level as can be across its width, using blocksto achieve this if necessary.

b. Supporting the front end of the trailer, manually or byusing the jockey wheel, if fitted, drop the front jacklegson to the pads provided with the trailer until the traileris approximately 2" lower than the level at the front(front end of the trailer down).

c. Drop the rear jacklegs onto the pads provided andtighten the jackleg screws.

d. Return to the front of the trailer and manually lifting thedrowbor for leverage, or simply winding the jockeywheel if fitted, raise the front end until it is level withthe rear end. Drop the front jacklegs and tighten thejackleg screws.

e. The whole trailer should now be 2" higher than normalwith the weight equally distributed between the fourjacklegs and the two wheels. Conway owners who havetrailers fitted with wind down corner steadies maymodify this procedure to obtain the same end result.


CONWAY

I, Remove the kitchen unit from D /L trailers at this point, Drop the four kitchen jocklegs until trey ore approximately l" from the ground, Tighten 188 jockleg screws, Release the Protex catches which .clomp the unit to the trailer and disconnect the 7 pin plug from the socket beneath the kitchen, Due to the ground clearance of the kitchen legs you ore now able to slide the kitchen unit away from the trailer body, Continue to slide the kitchen unit along the two kitchen support bars that extend from the rear of the trailer body. When the retaining brackets which ore fitted to the underside of the kitchen unit ore free from the support bars you may then lift the kitchen unit away from the trailer body, Adjust the kitchen legs to a safe working height once the trailer is erected. Release the kitchen support bar locking screws and push in both support bars,

If at this point the kitchen unit is not required i,e, a quick overnight stop en-route, then it con be stored along side the trailer body, under cover below bedboord level, before the trailer is erected.

g, This is now your stable platform for erecting your trailer tent by following the step by step instructions,

THE MAIN AIM

Taut Canvas Whenever you erect your Conway trailer tent your canvas should be "as tight as a drum skin",

Both roof and walls, in height, width and length should have this appearance - nothing less will do, the benefits ore both visible and long term,

PITCHING'

A tout canvas will:

o, Shed rainwater quicker and therefore dry sooner.

b, Withstand high winds better than slack, flopping canvas,

c Resist natural shrinkage - giving a longer, serviceable canvas life,

d, Eliminate chafing on the frame - up holding its appearance,

e, Maintain a safe distance between itself, and your sleeping comportments when wet,

The Conway cabins poles, extension legs and the bed legs ore independently adjustable to help you achieve your aim despite uneven ground, It is important to extend the cabin frame fully ie, fifth hole, on every outing, It con of course be reduced to suit ground variation, but always attempt ta achieve the highest setting possible,

A level trailer with level beds is ideal but there may well be times when to pitch on a severe slope is unavoidable. It is safer to allow the trailer to follow the line of the slope, end to end to ensure the canvas is taut when pegged, It may mean you hove to sleep at a slight angle, but your unit will be securely pegged,

Before Pegging Out: With the cabin frame extended as for as possible, check that the canvas is sitting correctly over both cabin and extension frames. Check that zip flops ore covering the zips as intended and that all zipped doors ore closed,

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PITCHING CONWAY

Fig. l Fig. 2

Conway Pegging Points: There ore loops of tape sewn into the bottom edge of all the canvas walls, within each tape loop ore both a rubber ring and a plastic 'D' shaped ring. It is important that only the pegging rubber, is used when pegging the canvas to the ground. It is both flexible and hard wearing in normal use but eventually you may have to replace a damaged pegging rubber.

The plastic 'D' ring is used only when a replacement pegging rubber is to be fitted. Do not use them for pegging. Replacement pegging rubbers (available from Conway dealers) are longer than normal pegging rubbers. After removing the damaged rubber this extra length allows you to:

a. Fig. 1 - Place the new rubber over both the sewn intape loop and the 'D' ring.

b. Fig. 2 - Thread the bottom of the new rubber back

through the centre of the 'D' ring.

c. Fig. 3 - Pull tight and peg os normal.

Knock pegs in at approximately 45 degrees to the ground for the best possible hold against the pull of the canvas. Only place pegging rubber on the peg once it is knocked in or damage may occur to rubber or canvas. General purpose pegs ore supplied with the trailer and your dealer will advise on the many other types available to suit all types of ground variations. Use the larger pegs supplied on all corners and guy lines and use smaller pegs on intermediate pegging points.

Peg out as per instruction diagram supplied with trailer.

Two types of guy lines ore provided, short ones which fasten to the eyeleted triangular flaps fitted· to the cabin walls around bedboord level and longer ones which fasten to the toped 'D' rings fitted at the roof corners.

The cabin wall guy points ore not strengthened and therefore not intended to hold the tent in storm conditions and require only slight tensioning. Correctly tensioned they will prevent wet canvas from touching the inner tents and mattresses in wet and windy conditions.

The 'D' ring guy points ore strong points, the tape which holds the 'D' ring continues through the seam to the inside of the canvas where it must be tied to the frame. This method ensures that both canvas and frame ore held securely in storm conditions.

Guy points ore not normally fitted where frame spikes protrude through eyelets fitted in the canvas eg. extension fronts, kitchen extensions and sun canopies. It is intended that guy lines be fitted directly over the spike itself.

As when pegging the canvas, pegs for the guy lines should be knocked in first before fitting guy line to the peg and adjusting by use of the sliding tensioner.

In extreme conditions 'storm props' and internal guy lines ore recommended. your dealer con advise on the types available.


C CONWAY

INTERNAL

When fitting inner tents, roof linings and toilet and wardrobe compartments it is important that the clips (metal or plastic) which suspend them are fitted over the frame, not under. If fitted incorrectly the end of these clips will be in contact with the canvas and damage will result. When fitted correctly only the smooth rounded face of the clip will be in· contact with the outer canvas.

FOLDING CAMPERS AND AWNINGS

Most of the suggestions in the previous chapters are applicable to folding campers and awnings. however, it is essential that the 'step by step' instructions for your unit ore followed closely.

LEVELLING

It is important to achieve an almost dead level unit, both side to side and end to end. Now that fridges ore standard equipment in most units, this is essential if the fridge is to work correctly. (see suppliers instructions)

Whilst end to end levelling is relative easy to obtain using the jockey wheel, the level from side to side must be obtained using blocks or proprietary caravan levellers (available from Conway dealers), not the corner steadies.

PITCHING

GUY POINTS

Hard Top Folding Campers Bright steel eye bolts ore fitted at each corner of the roof. They ore for storm guys, do not use for owning roof pole attachment.

DOOR OPENING

Folding Campers Over excessive use of the corner steadies can flex the trailer body causing the door to bind. This can also happen to the door on hard top models when the optional awning is fitted, by inadvertently pulling the roof toward the door side when pegging the owning out. To counteract this the roof can be guyed out so that it remains vertical.

iHmj Do not attempt to lift or support the

unit on the corner steadies alone, they are to

steady the unit when level.

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PITCHING

TROUBLE SHOOTING - All Models

Condensotion

a. Location - Check under mattresses doily.Remedy - Lift daily and air to prevent mildewforming, insulating mats will cut this drastically butcheck even so.

b. Location - Usually visible on framework and insidethe outer canvas in wet weather - do not confuse withleaking canvas.Remedy - Extra ventilation.

Difficult zips

a. Location - Main doors and side roll up sections.Remedy - cross peg rubbers at start of zip to relievezip tension.run zip teeth lightly with hard wax candle to lubricate.Ensure zip ends are equally and fully home beforepulling sliders (moulded zips).

Loose Canvas

Incorrect pegging or loose pegs/ Frame setting incorrect.

a. Location - Check pegs and guy lines doily.

Remedy - Try a different type of peg (s).- Change the angle of the peg (s) or relocate thepeg(s).- On hard ground - use an old screwdriver or pointedmetal bar for the pilot for peg(s.- Adjust poles to a higher position.

CONWAY


c� CONWAY

ALL MODELS

It is essential to follow the 'step by step' instructions for your model to avoid damage.

Wipe down the mudwall and base panel where necessary. Run through Section 3 'Preparing for the Road.'

Corry sturdy plastic bags for your groundsheet and pegs - they will both be soiled ond the groundsheet possibly damp underneath. Excess soil on angle pegs should be scraped off now.

TRAILER TENTS

If the canvas is wet, shake off the excess water. Wet or dry ensure the waterproof cover is between the canvas and bedboard (older models use the groundsheet or a plastic sheet) place folded extension canvas (s) on top with the extension frame(s) across the front. This helps to ensure the trailer is nose heavy. Check that no canvas is trapped in the cabin side frames (see arrows on diagram) or under the extension frames as this will cause chaffing in transit and is not covered under the warranty terms.

LEAVING SITE

Inner Tents

Unclip them from the frame, fold neatly on the mattress and they can be folded in with the mattress and bedboard.

FOLDING CAMPERS

If the canvas is wet shake off the excess water. Turn the mattresses vinyl side up or fit the waterproof nylon cover provided (depending on model). Ensure that no canvas i s trapped in the frame or bed runners.

Inner Tents

Unclip them from the frame/brackets, fold neatly and they can be left on the mattress, if the canvas is dry.

Important: Don't forget to make one lost check of the pitch before leaving the site.

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CANVAS CARE

SHRINKAGE

This does occur with cotton materials, even the best materials do so especially in the early period of service. Fortunately the characteristics of good quality canvas are well known to experienced campers and are easily dealt with. Shrinkage is more noticeable in new canvas, and after soaking and drying it out a few times the fibres will stabilise and any variations will become negligible. The greatest cause of shrinkage is wet cloth in a relaxed state and not under tension. To correct shrinkage erect the canvas, peg out tautly and thoroughly wet. Allow the canvas to dry out under tension, making sure all zips are closed.

WET PATCHES

After a period of use it is possible to find wet patches appearing in an otherwise perfectly waterproof canvas. Do not immediately blame the proofing, there could be other causes.

A prime culprit is detergent such as washing up liquid or childrens blow bubble mixture contaminating the canvas which breaks down the proofing. Proofed cotton relies on su�oce tension to keep out the water and still allow the canvas to breathe. Detergents ore 'wetting agents' designed to break down surface tension and as the advertisement soys 'a little detergent will go a long way'.

C COMWAY

SOILING

Try not to camp under trees, sop from the leaves will cause the proofing to break down. Bird droppings or soiling by a dog or cat hos the some effect.

In all coses wash the area with a warm, mild soapy solution using pure soap or soap flakes, then thoroughly rinse with water until you are satisfied it is clean, allow to dry. Re-proof the area with a silicone proofer, eg. Fosbil or similar, and allow to dry, ensuring the canvas is tout at all times. Repeat if necessary.

CLEANING AND RE-PROOFING

Do not allow household aerosols, eg. fly spray, air freshners, to come into contact with the canvas. To clean mud and marks from the canvas, hondbrush when the canvas is dry.

Your canvas will eventually require re-proofing. A regularly proofed tent will resist fading and mildew. How often should you re-proof? It is hard to specify a time, it depends on usage, three weeks near the beach with sea air and bright sunlight can be as severe as three seasons normal use. Your dealer should be able to recommend when it is necessary and usually offer a reproofing service and a regular repair service.

INNER TENTS, LININGS, CURTAINS AND LOOSE COVERS

Dry clean only - new clips ore available from your Conway �

dealer for these items.


MILDEW

This is the main enemy of your canvas, curtains, inner tents, roof linings and mattresses. This destructive parasitic fungus mould con spread from the smallest canvas section and quite quickly wreak havoc throughout your unit.

It is caused by only one thing - a failure to completely dry out, or at least expose to the air, damp or wet items within 48 hours. Don't overlook items subiect to condensation.

The first signs of mildew are:

The distinct mouldy smell. The appearance of purple spots which turn black, which in turn spread to black patches which disintergrate when touched.

If caught early enough they con be treated by either solutions of 'Milton' sterilising fluid or a solution of diluted bleach i.e. one desert spoon of bleach to a gallon of water or proprietary stain removal aids which ore available from your Conway dealer or chemist.

The treated oreo would also require re·proofing when dry.

imjjj Prevention is better than cure, ond

a cure may not always be possible!

CANVAS CARE

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FRAME CARE

To provide strength and stability the frame parts are made af steel and either zinc passivated ar polyester epoxy resin powder coated to protect the outer surface.

Zinc passivated finished frame parts are used on frames which need to be extended. It is a long lasting, hard wearing finish under normal conditions and requires minimum care and maintenance. Wipe down after use and (protecting the canvas) apply any automotive wax finish to the frame only and buff lightiy, DO NOT use canvas waterproofing liquid on frame parts. Restore the finish on old frames with zinc based metal paint.

Polyester epoxy resin powder coated frame parts are generally used where they are expected to be in permanent contact with totally enclosed outer canvas i.e. canvas which is not normally removed for winterstorage. Treat as zinc passivated with automotive waxafter use or winter storage, treat chips or scratcheswith zinc based metal paint.

Due to environmental considerations cyanide is no longer used in the Conway plating process and therefore oxidisation (white rust) can be evident after a period of use. Remove the white powder with a cloth or wire wool and treat with automotive wax, as normal.

CONWAY

FRAME MAINTENANCE

POLE CONNECTING SPRINGS Are intended for the ease of assembly of a series of poles only. If stretched or damaged in use replacements can be obtained from your Conway dealer. Due to the risk of iniury when removing a damaged spring it is advisable to ask your dealer to demonstrate the method of replacing pole connecting springs.

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C CONWAY

BUTTON CLIPS

Frame adjustment 'button clips' as they ore known, consist of a 'V' shaped metal spring clip with a button fitted. The button is normally all that is visible and is the port you depress to adjust the cabin frame poles, extension frame legs and the bed support legs on most models.

If damaged or lost (sometimes inside the pole) they ore easily replaceable. The 'V' spring clip is simply inserted into the end of the pole, closed end first. The open end of the spring clip with the button fitted is lined up with the location hole in the pole. Squeeze the spring clip and push fully into the pole. using o peg, screwdriver or similar thin bar, push the spring clip along until the 'button' pops through the location hole.

Button clips ore ovoiloble from, and con also be fitted by your Conway dealer.

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FRAME CARE

CABIN FRAME

HINGE MOUNTING POINTS

On older models, bolts with nylon nuts were used, later models use a metal pin secured by silver, domed cops of various sizes depending on location and model. The technical names for these cops ore 'quickols' or star lock washers.

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TRAILER CARE

ALL MODELS

Important: Keep all cleaners and detergents away from the canvas.

TRAILER TENTS (and certain folding Camper Models)

Body Panels OUTSIDE - wash with proprietary automotive cleaners which OLe non abrasive. For extra protection use automotive wax.

INSIDE - wipe down with a damp cloth and household cleaners on the pre-pointed body panels, lockers and vinyl floor. Dry thoroughly before storing.

Chassis and Drawbar Pointed - clean as per outer body panels. Check for stone chips and touch in with a zinc based metal paint or 'Hommerite' where needed.

Galvanised - clean as per the outer body panels. Remove with a hard bristle brush any excess oxidisation (white rust) and rinse with clean water. White rust is a natural reaction of galvanising and is no detriment except visually. Use zinc based metal paint on scratches penetrating the galvanised surface.

Up·hosltery and Carpets These should be vacuumed regularly as in your own home, to remove grit and sand. A mild solution of worm soapy water can be used ta remove day to day marks or stains.

CONWAY

FOLDING CAMPERS

Body Panels Are acrylic pre-painted aluminium bonded sides and/ or fibreglass (GRP), front and rear panels.

OUTSIDE - clean with proprietary automotive cleaners which are non abrasive and safe for acrylics.

INSIDE - the furniture and wall panels have an easy clean finish and only require a wipe down with worm soapy water or general household cleaner solution to maintain a clean smart finish.

Chassis and Drawbar Glavanised - clean as per trailer tents.


COMWAY

TRAILER TENTS

All Conway trailer tents have an easily removable cabin canvas for repairs or winter storage. They simply untie from the cabin frame. Wherever possible remove all canvas ports, inner tents, roof liners and mattresses and store in a worm, dry environment.

FOLDING CAMPERS

Whilst the cabin canvas can be removed for easy repair situations it is not as simple as the trai ler tents. We recommend that other items such as inner tents, roof liners and up-holstery be stored where possible in a worm, dry environment.

im)ij When the canvas, inner tents, roofliners etc; are not removed from the trailer tent

or folding camper we would recommend frequent checks are made, including opening and airing

the unit to prevent damage from codensation and possible mildew.

WINTER STORAGE

ALL MODELS

a. Jack up the unit using o suitable vehicle iock, locatedunder the axle beam until the wheels ore clear of theground. Do one side at o time with the handbrake on orwith the wheels chocked.

b. Place blocks of timber under the axle beam where itioins the chassis or use axle stands to support theweight of the trailer. Lower the iocklegs or cornersteadies to steady the unit only.

c. Release the handbrake, if fitted and leave it off, spinthe wheels from time ta time during the storage periodto ensure the wheel bearings are coated in grease,preventing rust spots. Lubricate all broke linkages.

d. Rain water, ice and snow should not be allowed taaccumulate on the transit cover. This will lead todiscolouration and deterioration of the cover.

e. Trailer tents should be slightly rear end down to preventrain water entering at the rear trailer door on standardmodels or the kitchen door on De luxe models.

f. Protect 7 pin plug(s) with a liberal applicationof petroleum ielly.

Remember: The winter period is the ideal time for both you and . your dealer if required, to attend to damage, defe� or servicing of the unit before the season starts .ogoin.

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GAS APPLIANCES USE AND MAINTENANCE CONWAY

GAS INFORMATION

Gas appliances fitted to Conway trailer tents and folding campers are of the LOW PRESSURE type and require a regulated gas feed. Liquid petroleum gas (LPG) should be used with a regulator giving the following pressures:

28m.bars (11.2 ins w.g.) for Butane (LPG) 37m.bars (14.8 ins w.g.) for Propane (LPG)

1/c,jtj Propane (LPG} continues to

operate at lower ambient temperatures than Butane (LPG}.

TRAILER TENTS

De Luxe models (D/L) of trailer tents are fitted with a double burner and grill. the gas connector is situated under the cooker unit and requires a push on gas hose connection, the hose should have a hose clip fitted to give a secure gas tight fit.

Full operating instructions for your cooker are included with this Manual.

FOLDING CAMPERS

Folding campers are fitted with a double burner and grill, and can have an underfloor heater and a fridge as optional extras.

FRIDGE (Where Fitted).

A complete separate instruction leaflet is enclosed giving full information on the operation of your refrigerator.

Towing with the Fridge When the camper is being towed it is recommended that the fridge is operated electrically, i.e. from the 12V battery of the towing vehicle and not by bottled gas. If the fridge is well frozen before starting your journey and your tow vehicle is fitted with a relay unit then the 12V power supply is adequate to keep the fridge 'topped up' only.

Starting the Fridge Before using your fridge for the first time it is advisable to wash the interior and its accessories. The fridge gas system includes a Piezo lighting device, and when the button is pushed in creates a spark. No batteries or flints are required to operate this lighter.

BEFORE STARTING YOUR FRIDGE ALWAYS CHECK that the alternative method of operation is OFF, two methods of operation CAN NOT be used at the same time.

If the camper fridge is to operate correctly ensure that the fridge is level.

SERVICE Should you require help or service in connection with your fridge please consult your manufacturers handbook for a list of European Service agents.


C'!: CO�WAY GAS APPLIANCES USE AND MAINTENANCE

UNDERFLOOR HEATER (Where Fitted). A complete separate instruction leaflet is enclosed giving full information on the operation of your heater.

Important: These heaters when fitted to folding campers ore perrectly safe to be used overnight. Ensure that they are not covered and all loose items are well clear. If fitted . · below the third bed, do not operate when bed is in use. They are never fitted to trailer tents. The exhaust gases would be lethal if confined within a totally enclosed outer canvas.

Starting 1. Make sure gas is turned on.

2. Remove dust shield, shield should never be replacedwith heater in use.

3. Start as per instruction manuol. On first lighting,the heater may smoke for a few minutes whileburners settle down, this is NORMAL.

In Use

Stepping on the grill is permissible but keeping feet on grill will damage your shoes and impair the circulation in the camper.

Packing up Always ensure the healer is turned off before closing the camper. Do not switch off the gas at the bottle first, this will DUrn off gas in the pipework which will fill with air resulting in difficulty in relighting the heater.

MAINTENANCE AND USE OF THE STAINLESS STEEL HOT PLATE AND SINK BOWL/DRAINER. A separate user instructions leaflet is also enclosed.

1. A protective plastic coating covers the top of thestainless cooker and, in some instances, the sink unitalso. THIS MUST BE REMOVED BEFORE USING.Under no circumstances should a burner be ignitedbefore the plastic is removed. If removal of the plasticcoating proves difficult it may be helpful to run warmwater onto the problem areas.

2. Any spillages should be removed from the stainless topas soon as possible after use. This can be done withhot soapy water and a nylon scouring pad (steelscouring pads should not be used). Stubborn markscan be removed by using a mild type of proprietaryclea�sing powder or cream. Care should be exercisedto see that the burners do not become choked withexcess powder or creom as this will result in unevenburning and flame spread, permanent discolouration ofthe stainless steel and 'sooting' of the burners.

3. The brilliance of the polished finish on both the cookerand the sink unit can be maintained by wiping overwith a soft cloth immersed in warm soapy waterimmediately ·after use. The surfaces should then bepolished with a dry cloth. An extra lustre can be givento the stainless steel by occasionally polishing withFrench chalk on a clean dry cloth. During use, it isnormal for 'blueing' of the burners and pan supportto take place. This discolouration will remain, despitecleaning, but will prove no detriment except visually.

I


GAS APPLIANCES USE AND MAINTENANCE

Use l. The hot plate is designed to operate with either

BUTANE GAS at a pressure of l l .2W.G. (28m.bor) orPROPANE GAS at a pressure of 14.SW.G. (37m.bor),or both.

The gos pressure regulator must be fitted at the outletof the gos bottle to provide the correct workingpressure. Check suppliers instruction sheet for lype(s)of gas to be used.

2. The control tops ore self locking in the OFF position andore all operated by depressing the knob and turning inan anti-clockwise direction. The FULL ON rote isobtained when the bar grip of the knob is vertical and aSIMMER rote when the knob is rotated to o positivestop 45 degrees post the vertical.

3. ADJUSTMENT - the mixture between gas and air tothe burners is preset on assembly and should notrequire adjustment.

imJij A small brigh t blue white flamecou ld mean too much air in the gas/air mixture. A yellow topped flame and sooting occurring means too little air in the mixture. If in doubt please contact your dealer for advice.

4. Ensure at all times that the 'ports' around theburners ore clean and free from obstructions fromspillages or excess cleaning cream. A small wirebrush will quickly clear any obstruction which maybe present.

5. SAFETY - as with any gos appliance normal safetyprecautions should be observed at all times butparticular care should be exercised when theappliance is used in a confined area.

DO NOT make any attempt to alter the injectors, taps, burners, or line pressure.

DO NOT use the hot plate as a space heater.

PLEASE NOTE:· it is recommended that in normal use a window or vent should be opened to provide ventilation. It should always be recognised that with the burners on and without ventilation the air in the folding camper will rapidly become exhausted.

DO NOT allow any combustible material eg. curtains, kitchen towels, to come into contact with" the appliance during the cooking process.

DO turn off the gas supply at the cylinder if you detect any unburnt gas.

GAS SYSTEM

a. Never laok for a leak with a match. Always check forleaks on connections with a soap solution. If the leak isnot obvious check with your dealer.

b. Avoid naked lights when connecting or changinga cylinder.

c. Gos is heavier than air therefore in the event of a leakgos will accumulate at floor level.

d. A fire extinguisher is advisable and they ore fitted as standard in certain models. The extinguisher should beof the dry powder lype and should be kept in a readilyaccessible position. Extinguishers of the vopourisingliquid lype should NOT BE USED.

e. In case of fire get everyone out of the unit, turn off thecontainer valve if possible and STAY OUT.


c� CONWAY

ALL YOU NEED TO KNOW ABOUT WIRING

YOUR VEHICLE FOR TOWING

12S SOCKET

No. Connection Colour

I. SPARE 2. CHARGER BLUE 3. EARTH WHITE 4. CONSTANT LIVE GREEN 5. SPARE 6. FRIDGE RED ]. SPARE

0

When having a tow bar fitted ensure the flasher relay unit is of the heavy duty type and the system is fitted with an audible warning device or dashboard light which operates when the trailer indicator lights are functional. When 12V power is required from the towing vehicle to charge an auxiliary battery, (via l 2S socket no 2) and/or run the fridge when towing (via l 2S socket no 6) then a single or 'combi' relay must be fitted to the towing vehicle. This will supply the maximum voltage available and protect the vehicle battery from accidental discharge. Always check road lights prior to starting your journey.

12N SOCKET

No. Connection Colour

I. L.H. INDICATOR YELLOW 2. FOG LAMP BLUE 3. EARTH WHITE 4. R.H. INDICATOR GREEN 5. RT SIDEL T. BROWN 6. BRAKES RED 7. L.H. SIDE LT. BLACK

Important: The wiring on the grey l 2S socket and the block 12N socket, whichever is applicable to your unit, is wired exactly as the above standards using the some colour coding and connection. For several years now since 1979, it become low for all trailers over 1.3 metres wide to require fog lights. The l 2S socket was introduced for the accessories in the unit and the 12N was used solely for th! rood lights.

•


I

WIRING OF CONNECTING CABLE

FOR MAINS INLET CONWAY

PITCH OUTLET CABLE PLUG INLET

GREEN & YELLOW (Earth)

CABLE SOCKET TERMINAL

BLUE (Neutroli BROWN (Live)

�

CABLE PLUG TERMINAL

GREEN & YELLOW (Earth)

MAINS INLET TERMINAL

''"�"··" GREEN & YELLOW

.(Earth)

« GREEN & YELLOW

(Earth) CABLE SOCKET OUTLET MAINS INLET

WARNING

Before connecting your unit to mains supply it is advisable to check with the site operator that the incoming mains polarity is correct. Where a mains connection is supplied the above diagram should be noted.

It is essential that connections ore mode exactly as shown. If terminal markings ore not in accordance with the above diagram consult a qualified electrician.

In case of difficulty consult on approved electrical installation contractor (who may be the local electricity board). It is dangerous to attempt modifications and additions yourself. lompholder, plugs (bayonet-cop adaptors) should not in any circumstances be used.

Preferable not less than once a year, the electrical installation should be inspected and tested and a report on its condition obtained as prescribed in the Regulations for Electrical Installations, published by the Inst itute of Electrical Engineers.


r:� "-"�

CONWAY CHASSIS AND RUNNING GEAR MAINTENANCE

BRAKE LINKAGE (BOWDEN CABLE)

OVER RUN BRAKING DEVICE

ADJUSTMENT

SERVICING Every I SOO miles or 6 monthly

Servicing Philosophy Grease the overrun coupling

The Conway lightweight chassis has been designed to be Check wheel bearing adjustment

maintained at its optimum performance level with Visually check the axle for damage

minimal servicing. Servicing philosophy embraces Check wheelbolt/nuts torque

lubrication inspections and adjustments carried out in Every 3000 miles or annually accordance with a schedule based on mileage. However, Check wheel bearing adjustment if the mileage is not attained, servicing should be Measure the towing boll carried out on a periodic basis. Grease the overrunning device

Servicing Schedule Check and adjust the broke shoes and the broke linkage

After first 20 miles Every 6000 miles or Biannually

Check wheelbolt/nuts torque Repack the wheel bearing hubs with grease

After first SOO miles Adjust the axial ploy of the wheel hub bearings

Check wheel bearing adjustment Check the broke linings for wear or fatigue Check and adjust the broke shoes and the broke linkage

Check and adjust the broke shoes and the broke linkage Lubricate the pivot pins of the running broke system Check wheelbalts/nuts torque

After use Servicing - Chassis Every SOO miles or 2 monthly

After journeys during winter, hose down to wash the Inspect all wheels salt off. After the trailer hos been immersed in water, hose Examine and lubricate the boll coupling down to remove any corrosive substances which may Inspect and lubricate the overrunning device attack the chassis. Lubricate the jockey wheel Lubricate the broke linkage Lubricate the corner steadies

I


THE AXLE & COUPLING CONWAY

Fig. l (a) Fig. l(b) Fig. l(c)

�·

· Q(e

REBOUND OR FREE POSITION NORMAL LADEN POSITION MAXIMUM BUMP

Fig. 2

THE AXLE

The Al-KO rubber suspension axle has been designed for new standards of spring comfort and is maintenance free.

Three rubber elements are contained within an hexagonal axle tube. These provide suspension and have inherent damping characteristics.

Figures. l(a) , (b) and (c) show the deformation of the rubber elements at the extremes of suspension movement.

The axle is designed to ride with the suspension drop arm at, or slightly below, the horizontal position.

THE COUPLING

The coupling is a standard 50mm. The cup of the coupling should be greased to prevent rattle and road noise. All other moving parts of the coupling should be lightly oiled occasionally. (Figure. 2) Braked Coupling

Examine all pivot pins and levers for correct operation and lubricate with oil.

Braked Models Only Check the handbrake ratchet for correct operation and lubricate with oil.

Grease the overrun shaft bearings via the grease nipples provided every 1500 miles or 6 monthly.


BRAKING SYSTEM

PARKING - HANDBRAKE APPLICATION

Very Important: When the handbrake is correctly applied it should be almost in o vertical position. Full application of the handbrake lever compresses a coil spring inside a steel cylinder and should any movement of the camper occur fallowing uncoupling the energy stored in the spring is immediately released to lock the wheel brakes.

The AL·KO automatic reversing broke system incorporates a patented device far added safety when parking on a reverse sloping site or a steep hill.

A spring cylinder has been added to the link between handbrake lever and centre broke rod.

It should be noted that it is good common practice to chock the wheels of a camper when parking on steep slopes, or under adverse weather conditions such as loose or slippery su�oces.

WHEEL BRAKE ADJUSTMENT

The AL·KO automatic reversing broke system and its linkage should be periodically odiusted to compensate for wear of the broke shoe lining and subsequent stretching of the bowden cables.

The trailer broke will be subiect to greater wear when used on continuous mountain iourneys.

The earner steadies should never be used to iock up the unit. When iocking becomes necessary, use a bottle, screw or scissor type iock. (AL·KO Port NO. 356858 with axle shaped head is recommended.) Place the iock plate under the axle as near as possible to the main longitudinal member.

CONWAY

Recommended Adjustment Procedure: a. Jock up the axle to raise the rood wheel clear of the

ground. Place a chock under the grounded wheel.

b. Ensure that the drowshoft is fully extended (in thetowing position) and the handbrake is OFF (fullyforward position). Confirm that there is some end floatin the rod and spring cylinder.

The brakes must be adjusted first and then, but only if necessary, the broke linkage. During wheel broke adjustment, the drum must only be turned in the direction of forward rotation. Do not use excessive force during adiustment.

c. Remove the plastic bung at the rear of the broke backplate and insert a suitable screwdriver into the hole.

d. Adiust the storwheel in the direction of the arrow untilthere is resistance to wheel movement.

e. Slacken until the broke drum turns freely in the forwarddirection.

f. Check for correct adiustment at the chassis end of thebowden coble. When pulled, the coble should extendbetween 5 and 8mm.

g. Check for uniform response by both wheel brakes when the handbrake is operated. Adiustment must be mode on the wheel broke, not on the broke linkage.


��

\._,.;' CONWAY

COUPLING HEAD \

HANDBRAKE LEVER I RUBBERSPRUNG AXLE

\

BRAKE LINKAGE I

\ \

BRAKING SYSTEM

ROTATION DIRECTION FORWARDS ....

·""-.

·,

I

BREAKAWAY CABLE SPRING CYLINDER COMPENSATOR PlATE1

\�OWDEN CABLE I

I \ i i i

i

BRAKE LINKAGE Al>-JUSTMENT

a. Apply the handbrake two or three times to ensure thatthe broke shoes ore centralised on the drum. Recheckshoe clearance at the wheel broke.

b. Centre broke rod · check that there is full threadengagement ill' the fork end of the overrunning device.Secure the locking nut.

c. At the axle, ensure that the compensator plate isparallel to the axle by adjusting the nuts on the bowdencables. Lock the nuts.

d. Adjust the centre broke rod at the rear nut so that thereis no clearance between the overrun lever and thedrowshoft and plate. Secure the locknuts.

e. Correct adjustment of the linkage is checked byoperating the handbrake lever so that it engages thesecond tooth of the ratchet and confirming that a slightbroking force is felt at the wheels.

f. On completion, tighten the self locking nut to givel mm clearance between the nut and the springcylinder. (Ignore this instruction if gos strut typehandbrake lever is fitted).

',

Important:

/ ./

Reversing will be difficult if either wheel broke or broke linkage is over-odjusted.

I


WHEEL BEARINGS & SERVICING CONWAY

CASTLE NUT & SPLIT PIN TAPER ROLLER BEARING (Fig. 6) PARALLEL BEARING (Fig. 7)

• 30 degrees ]/12th

TAPER ROLLER BEARINGS 1982 on

After the first 500 miles and at intervals of 1500 miles or 6 monthly thereafter, examine the wheel bearing hubs for side ploy.

Adjustment (Fig. 6) a. Remove the push-in grease cap. (It may be freed

by tapping lightly around its edge).b. Remove the split pin and tighten the castle nut

(right hand thread) until free rotation of the drumis impaired.

c. Slacken off the castle nut 1 /12th of a turn (30degrees) until one of its slots is aligned with crosshole in the middle of the stub axle.

d. Using a new split pin, secure the castle nut.e. Ensure the drum is free to rotate.f. Refit the push-in grease cap.

Recommended Lubricants Mobilgrease MP is recommended for all greasing routines. A good all-purpose oil recomended for general use.

..

PARALLEL BALL BEARINGS 1982 - '89

After the first 500 miles and at intervals of 1500 miles, or 6 monthly thereafter, examine the wheel bearings for side play.

Adjustment (Fig. 7) a. Remove the push-in grease cap. (It may be freed

by tapping lightly around its edge.)b. Remove the split pin and tighten the castle nut,

or nylock nut if fitted, by use of a torque wrenchas follows:Tighten initially to 301bs/ft.Back off and re-tighten to 151bs/ft.

c. If the castle nut is fitted - re-secure with a newsplit pin.

d. Ensure that the drum is free to rotate.e. Refit the push-in grease cap.

Important:IN:CORRECT ADJUSTMENT WILL RESULT IN BEARING

DAMAGE OR EXCESSIVE WEAR.

ju,Jij Double Row Ball Bearings fitted to some models from March 1994 - see info sheet or contact Conway for details.


CONWAY

Tyre size Type Circa

400 X 8 Crossply Pre '88

400 X 8 Crossply '91,92,93

400 X 8 Crossply '94 On

440 X l 0 Crossply Pre '88

145SR10 Radial '88 On

155SR13 4Ply Radial '82 On

155 R 13 Reinforced Radial '94 On

TYRES

It is dangerous to drive with under inflated tyres. The pressure (cold) recommended by tyre manufacturers should be regarded as minimal.

Check the tyre size fitted to your trailer.

Pressure checks, including spare tyre should be mode with the tyres cold, before each journey and at regular intervals during storage using on accurate pressure gouge.

it't,)jj 400x8 tyre pressures shou l d be checked during fuel stops on long iourneys

TYRE WEAR AND DAMAGE

The legal requirements for tread depth on motor vehicles apply also to trailer tents and !aiding campers. In order to equalise wear, it is suggested that wheels con be balanced and changed around from time to time. It is dangerous to neglect tyre damage and should you detect a blister, rupture or cut exposing the casing or ii it has suffered a violent impact (for exom�e against a kerb) such that there is a risk of internal damage, it must be demounted and examined by a tyre specialist as soon as possible.

TYRES AND ROADWHEELS

PSI Min Press (cold) Bar

45 3.1

33 2.3

55 3.8

45 3.1

32 2.2

35 2.4

39 2.7

WHEELS

The condition of wheels should be checked regularly paiticularly far distortion of flanges and the wheel dish.

Wheels damaged or distorted, or having wheel bolt seatings crocked or deformed must not be repaired or used in service.

Important: Wheel baits should always be tightened using a spider or similar tool (not the corner steady brace) to our recommended torque setting:

Wheel bolts- 651bs/ft (9.0kg/m)

Wheel nuts - 621bs/ft (8.0kg/m)

The torque setting should be re-checked ofter the first 20 miles of use then ofter the next 50 miles of use and then every 1500 miles or 6 monthly.

Many experienced campers check them at the start of every journey.

•it,)ij Both 155 13 Tyre types con be used

on some axle with min. tyre pressure of

35 PSI (2.4 Bar J

•


I

TYRES AND ROADWHEELS

PUNCTURES/WHEEL CHANGING

In every case try to ensure, for sofetys sake, as much clearance as possible between you and passing traffic.

Wherever possible leave the trailer connected to the tow vehicle. This will aid stability when on the jock. If this is not possible, lower the jockey wheel and chock this and the rood wheels. If the trailer is braked, apply the handbrake fully.

Lower the jacklegs or wind-dawn corner steadies until they are touching the ground as a safety measure only. Do not use them to jack up the trailer. A scissors, bottle or screw type jack should be used.

Locate the jack beneath the axle beam or mounting plate only. Do not use the chassis as a jacking point.

Slacken the wheel bolts/nuts - maximum one turn only, using a suitable spider or wheel brace.

Slacken the bolts of the underslung spare wheel carrier (if fitted) and if space permits remove the spare form its carrier

Jack up the trailer, remove the wheel bolts/nuts and change the wheel, it is recommended that you examine the new wheel before fitting. Refit the wheel bolts/nuts and tighten gradually in a North, South, East, West sequence.

Raise the corner jacklegs or wind up the earner steadies and then lower the jack fully and rel)love.

Using the sequence above, fully tighten the wheel baits/nuts. remember to check them after the first 20 miles preferable with a torque wrench where possible.

If the trailer is braked, remove the handbrake before moving off.


r� '--�

CONWAY

Conway Products Limited Skull House Lane, Appley Bridge, Wigan, WN6 9DW, Lancashire, England.

Tel: (01257) 254535 Fax: (01257) 254547

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